Copper Catalyst Ethanol Methanol Co-production
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Solution Overview
Problem
Current methods for producing ethanol and methanol face challenges such as high costs due to the use of precious metals, low selectivity, and dependence on fossil fuels, with existing technologies not efficiently utilizing synthesis gas for co-production of both chemicals.
Innovation Solution
A method involving a reactor with a catalyst composed of copper, optionally zinc and aluminum, and promoters like manganese, molybdenum, subjected to reduction treatment, where synthesis gas and acetate are co-fed to produce ethanol and methanol under specific temperature and pressure conditions, facilitating high activity in acetate hydrogenation and carbon monoxide conversion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If precious metal catalysts (Rh, Co, Ru) are used for ethanol synthesis from synthesis gas, then the activity and selectivity are improved, but the production cost increases significantly
Solution Approach 1:
The patent replaces expensive precious metal catalysts (Rh, Co, Ru) with a cheap copper-based catalyst system. The catalyst comprises CuO as the active component (50-100 wt%), combined with ZnO (0-35 wt%) and Al2O3 (0-10 wt%) as support/promoter materials. This substitution dramatically reduces catalyst cost while maintaining acceptable activity and selectivity for ethanol synthesis from synthesis gas and acetate.
2Adaptability or versatility
If fermentation method is used to produce ethanol, then the raw material source is renewable, but the dependence on crops increases and food supply is affected
Solution Approach 1:
The patent extracts the ethanol synthesis pathway from the biological fermentation process and implements it through a catalytic chemical process. Instead of using crop-based fermentation, the invention uses synthesis gas (derived from coal, natural gas, or biomass gasification) as feedstock with a copper-based catalyst to directly produce ethanol. This separates ethanol production from food crop consumption, allowing renewable energy production without competing with food supply.
3Productivity
If ethylene hydration method is used to produce ethanol, then the production efficiency is high, but the dependence on petroleum resources increases
Solution Approach 1:
The patent changes the fundamental reaction pathway from ethylene hydration (petroleum-based) to synthesis gas hydrogenation with acetate co-feeding (coal/natural gas/biomass-based). The process uses CuO-based catalyst to convert synthesis gas and acetate into ethanol through hydrogenation reactions. This parameter change in feedstock source and reaction mechanism maintains high production efficiency while eliminating dependence on petroleum resources.
4Productivity
If co-feeding synthesis gas and acetate is used for ethanol production, then the carbon monoxide conversion activity is improved, but the reaction conditions become more complex
Solution Approach 1:
The patent merges two functions into one reactor system: (1) hydrogenation of acetate to ethanol, and (2) conversion of carbon monoxide to methanol. The CuO-based catalyst simultaneously catalyzes both reactions, and the co-feeding of synthesis gas and acetate enables coupled production of ethanol and methanol in a single pass. This integration simplifies the overall process architecture despite the enhanced chemical complexity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method effectively synthesizes ethanol and coproduces methanol with high selectivity, allowing for flexible product ratios and reduced costs, enhancing the operational flexibility and market adaptability of the process.
Implementation Method 1
passing a raw material gas containing an acetate and a synthesis gas through a reactor loaded with a catalyst to produce ethanol and coproduce methanol
Implementation Method 2
catalyst composed of copper, optionally zinc and aluminum, and promoters like manganese, molybdenum, subjected to reduction treatment
Data Source
AI summary
This invention discloses a method for producing ethanol and coproducing methanol on a catalyst in a reactor using a co-feed of a synthesis gas and acetate as a reaction raw material. More particularly, this invention provides a method for producing ethanol and coproducing methanol, characterized in that the method comprises the step of passing a raw material gas containing an acetate and a synthesis gas through a reactor loaded with a catalyst to produce ethanol and coproduce methanol under the conditions of a reaction temperature of 150-350°C, a reaction pressure of 0.1-20.0 MPa, a reaction volume hourly space velocity of 100-45000 mlg-1h-1, and an acetate weight hourly space velocity of 0.01-5.0 h-1; and the active components of the catalyst are copper and optionally zinc and/or aluminum. The method of this invention greatly facilitates the conversion of carbon monoxide to methanol, while an extremely high activity of acetate hydrogenation is maintained. Also, the method of this invention produces ethanol while a certain amount of methanol is coproduced, and the proportions of ethanol and methanol may be adjusted, which increases the flexibility of products.